Headlamp Cylindrical Lens Structure for Overhead Sign Lighting
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Solution Overview
Problem
Existing headlamp designs that incorporate refractive structures for obtaining overhead sign (OS) functions negatively affect the outer appearance, complicating production and increasing error potential.
Innovation Solution
Integrate a refractive structure, such as a prismatic section of cylindrical lenses, on an optical component within the headlamp, tilted at an angle of 10° to 20°, to deflect light above the light/dark boundary without significantly impacting the headlamp's external appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a secondary optical element with discrete bumps is used to obtain OS function, then the overhead sign values are achieved, but the production complexity increases and the outer appearance is negatively affected
Solution Approach 1:
The patent changes the geometric parameters of the cylindrical lenses by tilting specific sections at angles between 5° and 30° relative to the optical axis. This parameter modification allows the same optical component to perform both light distribution and OS functions, eliminating the need for separate bumps and reducing production complexity while maintaining aesthetic appearance.
2Illumination intensity
If a secondary optical element with discrete bumps is used to obtain OS function, then the overhead sign values are achieved, but the outer appearance is negatively affected
Solution Approach 1:
The patent applies local quality by tilting only specific sections of the cylindrical lenses rather than the entire surface. This localized modification creates the necessary light deflection for OS values while keeping the majority of the optical component's surface smooth and aesthetically pleasing, thus resolving the appearance contradiction.
3Object-affected harmful factors
If the entire headlamp is designed to fulfill the requirement of projecting very little or no light above the light/dark boundary, then the low beam requirements are met, but the overhead sign values cannot be achieved
Solution Approach 1:
The patent implements local quality by creating distinct functional zones within the cylindrical lenses. Most of the lens surface maintains the low beam function by directing light below the light/dark boundary, while specific tilted sections locally redirect light into the overhead sign area. This spatial differentiation of optical functions resolves the contradiction between low beam requirements and OS value achievement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Achieves the OS function while maintaining the headlamp's aesthetic integrity by minimizing the visible impact of the refractive structure, ensuring effective light distribution and compliance with photometric requirements.
Implementation Method 1
A section of at least one, preferably numerous cylindrical lenses is therefore tilted in relation to the plane of the cylindrical lenses. This is practically imperceptible to anyone looking at the it. It can nevertheless deflect light into the area above the light/dark boundary in order to obtain the OS function.
Data Source
AI summary
A headlamp for a motor vehicle includes at least one light source, and an optical assembly containing numerous optical components. The optical assembly shapes light from the at least one light source and project it into the area in front of the motor vehicle such that a low beam light distribution is generated by the headlamp. The low beam light distribution has a light/dark boundary and a portion of light for obtaining an OS function above this light/dark boundary. A refractive structure deflects light passing through the refractive structure to obtain the OS function in the area above the light/dark boundary. One of the optical components contains an array of cylindrical lenses. The refractive structure is formed on the optical component that has the array of cylindrical lenses.